CN114545872A - Visual monitoring method and system for running state in production process of cigarette making machine equipment - Google Patents
Visual monitoring method and system for running state in production process of cigarette making machine equipment Download PDFInfo
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- CN114545872A CN114545872A CN202111534826.2A CN202111534826A CN114545872A CN 114545872 A CN114545872 A CN 114545872A CN 202111534826 A CN202111534826 A CN 202111534826A CN 114545872 A CN114545872 A CN 114545872A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32339—Object oriented modeling, design, analysis, implementation, simulation language
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a visual monitoring method and a system for the running state of a cigarette machine device in the production process, wherein the method comprises the following steps: step1, building an equipment digital model; step 2, acquiring data and acquiring perception information related to parts of the cigarette machine in real time; step 3, comparing the perception information with preset parameters to judge whether the parts of the cigarette machine equipment are abnormal or not; and 4, displaying the abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visual mode to dynamically monitor the cigarette machine equipment. The invention can directly control the running state and parameters of the cigarette making machine equipment through the three-dimensional human-computer interaction interface, acquire and check the real-time state of the production and running of the equipment, provide a comprehensive equipment management function, meet the comprehensive management of the production and running process of the equipment and reduce manual operation.
Description
Technical Field
The invention relates to a storage medium and a system of a monitoring method, in particular to a visual monitoring method and a system of an operation state in a production process of cigarette making machine equipment, and belongs to the technical field of tobacco processing control.
Background
Generally speaking, with the rapid development of an intelligent technology and an internet of things technology, various devices are interconnected and intercommunicated, in order to meet the requirement of data analysis, the types of sensors additionally arranged on the devices are more and more, more and more modules needing to be integrated are required, the development complexity is increased, and the traditional production line is generally developed by two-dimensional industrial monitoring software, is subject to many limitations, has obviously insufficient support capability on an information system with three-dimensional visualization requirement, is not as intuitive as a three-dimensional scene system in expressive force of the devices, and is lack of unqualified quality caused by product due to abnormity when parts are used, so that the product quality cannot be ensured; meanwhile, the traditional mode system development has the problems of large program structure size, difficulty in upgrading, incapability of rapid deployment and the like, and the application range of the system is reduced.
Therefore, the development of a visual monitoring method and system for the operating state of the cigarette making machine in the production process, which can directly monitor the operating state and parameters of the cigarette making machine through a three-dimensional human-computer interaction interface and acquire and check the real-time state of the production and operation of the equipment, is a key point for solving the technical problems.
Disclosure of Invention
Aiming at various defects and shortcomings in the background art, the invention provides a visual monitoring method and system for the running state of cigarette machine equipment in the production process, which can directly control the running state and parameters of the cigarette machine equipment through a three-dimensional human-computer interaction interface, acquire and check the real-time state of the production and running of the equipment, provide a comprehensive equipment management function, meet the comprehensive management of the production and running process of the equipment and reduce manual operation.
In order to solve the problems and achieve the purposes, the method and the system for visually monitoring the running state of the cigarette making machine in the production process are realized by adopting the following design structure and the following technical scheme:
a visual monitoring method for the running state of a cigarette machine device in the production process comprises the following steps:
step1, building an equipment digital model;
step 2, acquiring data and acquiring perception information related to parts of the cigarette machine in real time;
step 3, comparing the perception information with preset parameters to judge whether the parts of the cigarette machine equipment are abnormal or not;
and 4, displaying the abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visual mode to dynamically monitor the cigarette machine equipment.
Preferably, in step1, the specific construction method of the device digital model is as follows: according to the mechanical and electrical data and data description related to the equipment, a mechanical model of the equipment is drawn by utilizing the SolidEdge, and the model is optimized through 3Ds Max to complete the digital model building of the equipment.
Preferably, in the step 2, the sensing information includes sensor data parameters, and the sensor data parameters include environment temperature and humidity information parameters, temperature information parameters, pressure information parameters, inlet moisture information parameters, wind speed and wind volume information parameters, outlet moisture information parameters, and motor rotation speed information parameters.
Preferably, in the step 3, when the sensing information is not within the preset parameter range, the cigarette machine equipment part is judged to be damaged, and the system automatically pops up a reminding item of the information to remind maintenance personnel to detect and maintain, determine whether the cigarette machine equipment part is abnormal or damaged, and guide personnel to replace or perform other operations.
Preferably, the step 4 includes positioning the abnormal device part information to the corresponding coordinate part position in the digital device model, and displaying the part information.
Preferably, the visual detection system for the running state in the production process of the cigarette making machine equipment comprises a construction module, a sensing module, a main control module and a visual module, wherein,
the building module is used for building an equipment digital model;
the sensing module is used for acquiring data and acquiring production product data and sensing information related to parts of the cigarette machine in real time;
the visualization module is used for displaying abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visualization mode so as to dynamically monitor cigarette machine equipment.
Preferably, the building module, the sensing module, the main control module and the visualization module are in data communication connection, so that data information intercommunication is realized.
Preferably, the building module is a building program module;
the sensing module is a sensing program module;
the main control module is a main control program module;
the visualization module is a visualization program module.
More preferably, the sensing module further comprises an ambient temperature and humidity sensor, a steam quality detection sensor, a temperature sensor, a pressure sensor, an inlet moisture sensor, an air speed and air quantity sensor, various air door detection sensors, an outlet moisture sensor and a motor speed encoder;
the visualization module also comprises equipment monitoring, equipment control, intelligent identification of spare parts, quality statistical analysis and equipment analysis management.
Still further preferably, the system further comprises:
the data acquisition module is used for acquiring preset parameters from the database and sending the preset parameters to the main control module;
and the third-party control system is connected with the main control module through an industrial Ethernet and is used for acquiring linkage information.
And the database is used for storing various data information.
Compared with the prior art, the invention has the following beneficial effects:
the invention can directly control the running state and parameters of the cigarette machine equipment through the three-dimensional human-computer interaction interface, acquire and check the real-time state of the production and running of the equipment, provide a comprehensive equipment management function, meet the comprehensive management of the production and running process of the equipment, reduce manual operation, and simultaneously provide more accurate and reliable equipment running prompt information for users, thereby effectively improving the practicability of the method and being beneficial to popularization and application in the market.
Drawings
Embodiments of the invention are described in further detail below with reference to the attached drawing figures, wherein:
FIG. 1 is one of the system block diagrams of the present invention;
FIG. 2 is a second block diagram of the system of the present invention;
FIG. 3 is one of the schematic diagrams of an embodiment of the present invention;
fig. 4 is a schematic diagram of the second embodiment of the present invention.
Detailed Description
In order to make the technical means, the inventive features, the achievement purposes and the effects of the present invention easy to understand, the technical solutions of the present invention are further described in detail with reference to the drawings and the detailed description below, and it is to be noted that the embodiments and the features in the embodiments in the present application can be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
The method for visually monitoring the operating state of the cigarette making machine in the production process comprises the following steps:
step1, building a digital model of equipment;
step 2, acquiring data and acquiring perception information related to parts of the cigarette machine in real time;
step 3, comparing the perception information with preset parameters to judge whether the parts of the cigarette machine equipment are abnormal or not;
and 4, displaying the abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visual mode to dynamically monitor the cigarette machine equipment.
Further, in step1, the specific construction method of the device digital model is as follows: according to the mechanical and electrical data and data description related to the equipment, a mechanical model of the equipment is drawn by utilizing the SolidEdge, and the model is optimized through 3Ds Max to complete the digital model building of the equipment.
After the digital model of the equipment is built, importing the digital model generated in Step1 into a system scene by using Unity software, defining corresponding nodes and model attributes, enhancing the system scene effect by introducing elements such as lamplight materials and the like, designing an interactive interface, and completing the building of a three-dimensional visual system scene.
As shown in fig. 1 or fig. 2, further, in step 2, the sensing information includes sensor data parameters, and the sensor data parameters include an environment temperature and humidity information parameter, a temperature information parameter, a pressure information parameter, an inlet moisture information parameter, a wind speed and wind volume information parameter, an outlet moisture information parameter, and a motor rotation speed information parameter.
Furthermore, in the step 3, when the sensing information is not within the preset parameter range, the system automatically pops up a reminding item of the information to remind maintenance personnel to perform detection, maintenance and the like, determine whether the parts of the cigarette making machine are abnormal or damaged, and guide the personnel to perform replacement or other operations.
Further, the step 4 includes positioning the device part information based on the abnormality to the corresponding coordinate part position in the digital device model, and displaying the damaged part information.
Specifically, in embodiment 1, as shown in fig. 3, under normal conditions, the normal value range of the inlet steam quality detection sensor of the cigarette making machine is preset to be 90-100%, if the detected value is 81%, an abnormal phenomenon occurs, the digital model pops up a reminding interface, the digital model is positioned to the position of a steam quality detection device, and sound and light alarm or color change is used for displaying and guiding maintenance personnel to perform judgment operation.
In embodiment 2, as shown in fig. 4, under normal conditions, the range of the normal value of the battery voltage of the sheet temperature detection sensor of the cigarette making machine is preset to be greater than 7V, at this time, the detection value is 6.56V, the digital model pops up a reminding interface, the reminding interface is positioned to the position of the sheet temperature detection device, and the reminding interface displays through sound and light alarm or color change to remind maintenance personnel to replace the sensor battery.
As shown in fig. 2, a visual detection system for operation status in the production process of cigarette making machine equipment comprises a construction module, a sensing module, a main control module and a visual module, wherein,
the building module is used for building an equipment digital model;
the sensing module is used for acquiring data and acquiring production product data and sensing information related to parts of the cigarette machine in real time;
the visualization module is used for displaying abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visualization mode so as to dynamically monitor cigarette machine equipment.
In the above whole implementation process, the main control module serves as an OPC SERVER, configures an OPC UA SERVER, and issues OPC variables, including: the production work order, the production batch, the production brand, the production class and the like are used for receiving the production task issued by the MES system;
according to communication interfaces and protocols provided by various sensing devices, the connection with a main control module is realized through an industrial Ethernet or a field bus, and various sensor and equipment data and the like are obtained;
the third-party system refers to a front-section system and a rear-section system of the cigarette making machine equipment, and the main control module and the third-party system establish communication through an industrial Ethernet to obtain linkage information; the upper MES system carries out OPC communication with the main control module through the Ethernet and transmits the production task to an OPC variable in the main control module;
the data acquisition module is communicated with the main control module to acquire all data opened on the main control module and store the data into a database at fixed time intervals;
the visualization module is communicated with the main control module to acquire all data opened on the main control module, receives the data of the main control module and displays the data on an interface according to the mapping relation between the data and the digital model, and dynamically simulates the operation of equipment in an all-round way, so that the state of the equipment is refreshed in real time, and the monitoring of field equipment is realized; meanwhile, an instruction can be sent to the main control module to control the equipment to operate;
the visualization module is associated with the data acquisition module through a database; according to real-time fault information acquired by the data acquisition module, when a fault occurs, the visualization system actively pops up an alarm information frame, clicks a positioning button, moves a display visual angle to the position of the faulted device in a three-dimensional interface, gives detailed description of the fault and a solution based on expert knowledge, and can click a related page entering a drawing where the faulted device is located.
As shown in fig. 1, in the drawing, a construction module is not shown, and an operation state visualization module is used in the production process of the cigarette making machine, and the construction module, the sensing module, the main control module and the visualization module are in data communication connection to realize data information intercommunication.
Meanwhile, the building module is a building program module; the sensing module is a sensing program module; the main control module is a main control program module; the visualization module is a visualization program module.
Furthermore, the sensing module also comprises an environment temperature and humidity sensor, a steam quality detection sensor, a temperature sensor, a pressure sensor, an inlet moisture sensor, an air speed and air quantity sensor, various air door detection sensors, an outlet moisture sensor and a motor rotating speed encoder;
the visualization module also comprises equipment monitoring, equipment control, intelligent identification of spare parts, quality statistical analysis and equipment analysis management.
The intelligent identification of the spare parts comprises the steps of establishing an equipment spare part management system according to spare part information provided by cigarette machine equipment, storing basic data information of the spare parts in a database, wherein the basic data information of the spare parts comprises spare part identity codes, specification models, drawing numbers, quantity, supplier information, warehouse entry and exit time and the like, and pictures located at the actual positions of a digital model or model-based coordinate guidance, and the spare part information can be displayed through a visualization module; when a user needs to replace spare parts, information of the spare parts needing to be replaced can be quickly called out according to the identity codes of the spare parts, and replacement parts can be quickly found according to information indication; meanwhile, recording the time and the consumption quantity of spare parts to be taken out of the warehouse, and updating the information of the spare parts in the database;
the quality statistical analysis carries out statistical analysis on the equipment process quality parameters, so that quality problems in production can be found in time, and the statistical result can guide production; the method specifically comprises the following steps: storing corresponding process quality standards to a database according to cigarette process standards and cigarette brands, wherein the process standard information comprises: standard set values, standard upper limit values, standard lower limit values, allowance and the like of the grade and equipment process quality parameters; according to screening conditions such as work orders, batches, brands, shifts and the like, automatically calculating statistical data such as maximum values, minimum values, average values, standard deviations, CPK (continuous processing), overrun points, qualification rates and the like of process quality parameters during batch production, and counting actual operation conditions of the process quality parameters, wherein the statistics on the basis of shifts and batches is supported when the work orders are produced in a cross-shift mode; introducing an SPC control theory, and drawing an X Bar-R control chart according to screening conditions and an SPC algorithm; the quality analysis result can be displayed through a visualization module.
The equipment analysis management manages the equipment, so that the real condition of the equipment can be reflected, and the utilization rate of the equipment is improved; the method specifically comprises the following steps: establishing an equipment maintenance management system, wherein maintenance basic information is stored in a database, and the method comprises the following steps: the maintenance code, the maintenance period, the maintenance name, the maintenance type, the maintenance content and the like, and the maintenance information can be displayed through the visual module; according to the starting and stopping states and the production conditions of the equipment, the running time, the fault stopping time, the maintenance time, the yield, the qualified rate and the like of the equipment are counted, and the production efficiency, the utilization rate, the fault rate, the production capacity and the like are statistically analyzed by combining corresponding algorithms.
The system further comprises:
the data acquisition module is used for acquiring preset parameters from the database and sending the preset parameters to the main control module;
and the third-party control system is connected with the main control module through an industrial Ethernet and is used for acquiring linkage information.
And the database is used for storing various data information.
According to the mechanical and electrical data and data description related to the equipment, a mechanical model of the equipment is drawn by utilizing the SolidEdge, and the model is optimized through 3Ds Max to complete the digital model building of the equipment.
Converting the model into an FBX format, importing a system scene by utilizing Unity software, defining corresponding nodes and model attributes of the model, dividing the model nodes according to the functional areas of the equipment, and comprising the following steps: the device comprises a device feeding end, a device discharging end, a hot air system, a moisture discharging system, a jacking system and the like; the model attributes include: data type attribute, action attribute, control attribute, and the like; the scene effect is improved by introducing elements such as lamplight materials and the like, an interactive interface is designed, the scene building of a three-dimensional visualization system is completed, and the Unity software script development adopts a C # programming language to realize the module function;
in order to receive the production task issued by the MES system, the main control module is used as an OPC SERVER, an OPC UA SERVER is configured, and OPC variables are issued, wherein the steps comprise: production work order, production batch, production brand, production shift and the like;
according to communication interfaces and protocols provided by various sensing devices, the connection with a main control module is realized through an industrial Ethernet or a field bus, and various sensor data and the like are obtained; the control program of the main control module is developed by adopting TwinCAT software;
the third-party system is a front-section system and a rear-section system of the cigarette making machine equipment, the rear-section system of the equipment sends a local operation signal to the main control module, the front-section system of the equipment sends a local operation signal to the front-section system of the equipment after the equipment is started, and the front-section system starts the local section after receiving the equipment operation signal so as to realize the linkage of the production line; the third-party system controller is connected with the main control module through the industrial Ethernet to obtain linkage information; the MES system communicates with the main control module through OPC UA to issue production tasks, and the production tasks are used for quality analysis, yield statistics and the like;
the data acquisition module is communicated with the main control module to acquire all data opened on the main control module and store the data into a database at fixed time intervals; the data acquisition module is developed by using C # software, and the database adopts an SQL relational database;
the visualization module is communicated with the main control module to acquire all data opened on the main control module, and the visualization module receives the data of the main control module and displays the data on an interface according to the mapping relation between the data and the digital model, so that the operation of the equipment is simulated dynamically in all directions, the state of the equipment is refreshed in real time, and the monitoring of the field equipment is realized; meanwhile, a production instruction can be issued to the controller to control the equipment to operate;
the visualization module is associated with the data acquisition module through an SQL database, when a fault occurs according to real-time fault information acquired by the data acquisition module, the visualization system actively pops up an alarm information frame, clicks a positioning button, moves a display visual angle to the position of the faulted device in a three-dimensional interface, gives detailed description of the fault and a solution based on expert knowledge, and can click a related page of a drawing where the faulted device is located;
the intelligent identification of the parts and spare parts of the equipment comprises the steps of establishing an equipment part and spare part management system according to the information of the parts and spare parts provided by the cigarette making machine equipment, storing basic data information of the parts and spare parts in a database, and guiding pictures located at the actual positions of the digital models or coordinates based on the models, wherein the basic data information of the parts and spare parts comprises part identity codes, specification models, picture numbers, quantity, supplier information, warehouse-in and warehouse-out time and the like, and the information of the parts and spare parts can be displayed through a visualization module; when a user needs to replace spare parts, information of the spare parts needing to be replaced can be quickly called out according to the identity codes of the spare parts, and replacement parts can be quickly found according to information indication; meanwhile, recording the time and the consumption quantity of spare parts to be taken out of the warehouse, and updating the information of the spare parts in the database; the user can conveniently count the spare parts and supplement the spare parts in time;
the quality analysis is completed through a quality analysis system, the quality analysis system carries out statistical analysis on equipment process quality parameters by utilizing collected historical production data, quality problems existing in production are found in time, and the statistical result can guide production; the method specifically comprises the following steps:
firstly, according to the cigarette process standard, storing corresponding process quality standard to a database according to the cigarette brand, wherein the process standard information comprises: standard set values, standard upper limit values, standard lower limit values, allowance and the like of the grade and equipment process quality parameters;
secondly, according to screening conditions such as work orders, batches, brands, shifts and the like, automatically calculating statistical data such as maximum values, minimum values, average values, standard deviations, CPK, overrun points, qualification rates and the like of the process quality parameters during batch production, counting actual operation conditions of the process quality parameters, and supporting statistics respectively according to shifts and batches when the work orders are produced in a cross-shift mode;
thirdly, introducing an SPC control theory, and drawing an X Bar-R control chart according to screening conditions and an SPC algorithm;
the equipment analysis management is accomplished through equipment analysis management system, and equipment analysis management system manages equipment, can reflect the true situation of equipment, improves equipment utilization, specifically includes:
firstly, establish equipment maintenance management system, maintenance basic information storage includes in the database: maintenance code, maintenance period, maintenance name, maintenance type, maintenance content, etc.; after each maintenance of the equipment, selecting a performed maintenance item, automatically calling out detailed maintenance information of the item from the database, pressing a maintenance registration button on a monitoring interface, automatically inputting a maintenance code, maintenance contents, responsible persons, starting time and ending time into the database, and automatically judging whether a maintenance task exists in the day or not according to maintenance records in the database and a maintenance period before the equipment is started by the system, and making an intelligent prompt;
secondly, the running time, the fault shutdown time, the maintenance time, the yield, the qualified rate and the like of the equipment are counted according to the starting and stopping states and the production conditions of the equipment, and the comprehensive efficiency, the utilization rate, the fault rate, the production capacity and the like of the equipment are subjected to statistical analysis by combining corresponding algorithms.
To sum up, the more specific embodiments of the present invention are:
step1, building a digital model of equipment
The visualization module of a drum-type thin plate cut tobacco dryer of a certain model in a certain tobacco fine cut tobacco manufacturing workshop is explained. Building a model, namely drawing a mechanical model of the cigarette making machine equipment by using SolidEdge according to the actual size by referring to a mechanical structure diagram of the cut tobacco dryer equipment, a detection device, a control box, an actuator and the like, and optimizing the model through 3Ds Max to complete the building of the digital model;
step 2, acquiring data and acquiring perception information related to parts of the cigarette machine in real time
Converting the generated digital model into an FBX format file, importing a system scene by using Unity, defining corresponding nodes and model attributes, setting illumination, light, materials, rendering and the like of a scene system, designing and distributing a human-computer interaction interface in Unity by combining drawing software such as PS, Visio and the like, designing the layout of the human-computer interaction interface, and completing the construction of a three-dimensional visual system scene;
in order to receive the production task issued by the MES system, the main control module is used as an OPC SERVER, an OPC UA SERVER is configured, and OPC variables are issued, wherein the steps comprise: production work order, production batch, production brand, production shift and the like;
in consideration of the intelligent requirement, various sensors for detection are additionally arranged on the equipment, such as: sensors for detecting ambient temperature, ambient humidity, cylinder wall temperature, hot air temperature, air quantity and air speed, steam pressure, moisture, steam quality and the like are used for constructing a data base platform; the device can be divided into DP and PA internet devices according to a communication interface and a protocol provided by the sensor, the PA devices can be integrated into a DP network by using a DP linker and a P + F gateway, and the DP network is linked by the main control module to realize the purpose of reading data of various sensors; the control program of the main control module is developed by adopting TwinCAT software;
the master control module is used as a slave station and mounted under a master station of a third-party control system to realize communication with the third-party control system, and is used for receiving the transmitted linkage information and controlling the operation of equipment; the MES system communicates with the main control module through OPC UA to issue production tasks, and the production tasks are used for quality analysis, yield statistics and the like;
the data acquisition module is developed by using C # software, and establishes communication between the TwinCAT.Ads dynamic library and the main control module to acquire all data opened by the main control module, such as: and storing the sensor data, the equipment data, the production data and the like into the SQL database at fixed time intervals.
Step 3, comparing the perception information with preset parameters to judge whether the parts of the cigarette machine equipment are abnormal or not
The visualization module is developed by using Unity software, communication is established between TwinCAT.Ads and the main control module, all data opened by the main control module are obtained, the visualization system receives the data of the main control module and displays the data on an interface according to the mapping relation between the data and a digital model, the operation of the equipment is simulated in an all-around way, the process flow dynamics, the material flow direction, the working state of the equipment, the control mode and the like of the equipment are refreshed in real time, the state information, the parameter information and the like of the equipment motor and a detection device are reflected in real time, and the monitoring of the field equipment is realized; meanwhile, production instructions can be issued, mode switching, parameter regulation and control and the like are carried out, and man-machine interaction is realized;
and 4, displaying the abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visual mode to dynamically monitor the cigarette machine equipment.
The visualization module and the data acquisition module are associated through an SQL database, the data acquisition module refreshes equipment fault information in real time and presents the information in a visualization system interface, when a fault occurs, the visualization system actively pops up an alarm information frame, clicks a positioning button, moves a display visual angle to the position of the faulted device in a three-dimensional interface, gives detailed description of the fault and a solution based on expert knowledge, and can click a related page of a drawing where the faulted device is located; according to the recorded fault information, the equipment fault time can be counted for equipment analysis and management;
in the whole implementation operation process, the intelligent identification of the parts and spare parts of the equipment comprises the steps of establishing an equipment part and spare part management system according to the information of the parts and spare parts provided by the cigarette making machine equipment, storing basic data information of the parts and spare parts in a database, wherein the basic data information of the parts and spare parts comprises identity codes of the parts and spare parts, specification models, numbers, quantity, supplier information, warehouse entry and exit time and the like, and pictures located at the actual positions of the digital models or coordinate guidance based on the models, and the information of the parts and spare parts can be displayed through a visualization module; when a user needs to replace spare parts, information of the spare parts needing to be replaced can be quickly called out according to the identity codes of the spare parts, and replacement parts can be quickly found according to information indication; meanwhile, recording the time and the consumption quantity of spare parts to be taken out of the warehouse, and updating the information of the spare parts in the database; the user can conveniently count the spare parts and supplement the spare parts in time;
the quality analysis system can be used for judging the production condition by utilizing the collected production process data; the statistical analysis is carried out on the equipment process quality parameters, the quality problems in production are found in time, and the statistical result can guide production; the method specifically comprises the following steps:
firstly, according to the cigarette process standard, storing the corresponding process quality standard to a database according to the cigarette brand, wherein one brand corresponds to one process standard, and each piece of process standard information comprises: standard set values, standard upper limit values, standard lower limit values, allowance and the like of the grade and equipment process quality parameters;
during production, the start and the end of a batch are automatically judged by combining the equipment state, the process quality parameter data is automatically stored into a database according to a time stamp when the batch starts, and data acquisition is stopped when the batch ends; according to screening conditions such as work orders, batches, brands, shifts and the like, automatically calculating statistical data such as the maximum value, the minimum value, the average value, the standard deviation, the CPK, the number of overrun points, the qualification rate and the like of process quality parameters during batch production, when a certain process quality parameter needs to be counted, reading the corresponding process parameter quality standard from a database according to the brand, performing online analysis in real time, presenting an analysis result in a visualization module for production personnel to look up, and if an abnormal phenomenon exists, adjusting the process parameters of equipment in time;
thirdly, introducing an SPC control theory, and drawing an X Bar-R control chart according to screening conditions and an SPC algorithm, wherein the steps are as follows:
1. selecting data (>50, multiple of 5 or 6) of normal production of equipment;
2. calculating the average value of every 5 or 6 data groups
Range R (the difference between the maximum and minimum values in a set of data);
3. drawing a control chart according to an SPC algorithm formula;
the control chart can analyze and judge whether the production process is stable or not, discover abnormal phenomena in the production process in time, prevent unqualified products from occurring and provide a basis for evaluating the product quality.
The equipment analysis management manages the equipment, can reflect the real condition of the equipment, improves the utilization rate of the equipment, and the analysis result can be presented in a visualization module, and the method specifically comprises the following steps:
establishing an equipment maintenance management system, wherein maintenance basic information is stored in a database, and the method comprises the following steps: maintenance code, maintenance period, maintenance name, maintenance type, maintenance content, etc.; after each maintenance of the equipment, selecting a performed maintenance item, automatically calling out detailed maintenance information of the item from the database, pressing a maintenance registration button on a monitoring interface, automatically inputting a maintenance code, maintenance contents, responsible persons, starting time and ending time into the database, and automatically judging whether a maintenance task exists in the day or not according to maintenance records in the database and a maintenance period before the equipment is started by the system, and making an intelligent prompt;
according to the starting and stopping states and production conditions of the equipment, the running time, fault stopping time, maintenance time, yield, qualified rate and the like of the equipment are counted, and the comprehensive efficiency, the utilization rate, the fault rate, the production capacity and the like of the equipment are subjected to statistical analysis by combining corresponding algorithms; part of the formula algorithm is as follows: the comprehensive efficiency is time starting rate multiplied by performance starting rate multiplied by qualified product rate, wherein the time starting rate is starting time/load time, the load time is calendar working time-planned downtime, the starting time is load time-fault downtime, the performance starting rate is machining quantity multiplied by theoretical machining period/starting time, and the qualified product rate is qualified product quantity/machining quantity;
finally, it should be noted that the above-mentioned embodiments are only preferred embodiments of the present invention, and are not intended to limit the present invention in other forms, and any person skilled in the art may change or modify the technical content disclosed above into equivalent embodiments with equivalent changes. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention are within the protection scope of the technical solution of the present invention.
Claims (10)
1. A visual monitoring method for the running state in the production process of cigarette machine equipment is characterized by comprising the following steps:
step1, building an equipment digital model;
step 2, acquiring data and acquiring perception information related to parts of the cigarette machine in real time;
step 3, comparing the perception information with preset parameters to judge whether the parts of the cigarette machine equipment are abnormal or not;
and 4, displaying the abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visual mode to dynamically monitor the cigarette machine equipment.
2. The visual monitoring method for the operating state of the cigarette making machine in the production process is characterized in that in the step1, the specific construction mode of the digital equipment model is as follows: according to the mechanical and electrical data and data description related to the equipment, a mechanical model of the equipment is drawn by utilizing the SolidEdge, and the model is optimized through 3Ds Max to complete the digital model building of the equipment.
3. The visual monitoring method for the running state of the cigarette making machine in the production process according to claim 1, wherein in the step 2, the sensing information comprises sensor data parameters, and the sensor data parameters comprise environment temperature and humidity information parameters, temperature information parameters, pressure information parameters, inlet moisture information parameters, wind speed and wind volume information parameters, outlet moisture information parameters and motor rotating speed information parameters.
4. The visual monitoring method for the running state of the cigarette machine in the production process of the equipment as claimed in claim 1, wherein in the step 3, when the sensing information is not within the preset parameter range, the parts of the cigarette machine are judged to be damaged, and the system automatically pops up a reminding item of the information to remind a maintenance worker to detect and maintain, determine whether the parts of the cigarette machine are abnormal or damaged, and guide the maintenance worker to replace or perform other operations.
5. The visual monitoring method for the operating state of the cigarette making machine in the production process according to claim 1, wherein the step 4 comprises positioning the abnormal equipment part information to the corresponding coordinate part position in the digital equipment model and displaying the part information.
6. A visual detection system for the running state of a cigarette machine in the production process is characterized by comprising a construction module, a sensing module, a main control module and a visual module, wherein,
the building module is used for building an equipment digital model;
the sensing module is used for acquiring data and acquiring production product data and sensing information related to parts of the cigarette machine in real time;
the visualization module is used for displaying abnormal cigarette machine equipment parts on a pre-built equipment digital model in a visualization mode so as to dynamically monitor cigarette machine equipment.
7. The visual detection system for the operating state of the cigarette making machine in the production process is characterized in that the construction module, the sensing module, the main control module and the visual module are in data communication connection to realize data information intercommunication.
8. The visual detection system for the operating state of the cigarette making machine in the production process is characterized in that the building module is a building program module;
the sensing module is a sensing program module;
the main control module is a main control program module;
the visualization module is a visualization program module.
9. The visual detection system for the running state of the cigarette making machine in the production process is characterized in that the sensing module further comprises an environment temperature and humidity sensor, a steam quality detection sensor, a temperature sensor, a pressure sensor, an inlet moisture sensor, a wind speed and wind volume sensor, various air door detection sensors, an outlet moisture sensor and a motor rotating speed encoder;
the visualization module also comprises equipment monitoring, equipment control, intelligent identification of spare parts, quality statistical analysis and equipment analysis management.
10. The module for visualizing operational status of a cigarette maker device as in claim 6, wherein the system further comprises:
the data acquisition module is used for acquiring preset parameters from the database and sending the preset parameters to the main control module;
and the third-party control system is connected with the main control module through an industrial Ethernet and is used for acquiring linkage information.
And the database is used for storing various data information.
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